Thermal and acoustical structural insulating composition

ABSTRACT

A coated thermally expanded mineral aggregate thermal and acoustical insulating structural composition and a process for its production is provided wherein a low consistency board furnish containing binder, defibrillated fibrous material and a relatively high percentage of glass reinforcing fibers is deposited on the surface of a partially dewatered mat containing defibrillated fibrous material, binder and 50-85 percent thermally expanded mineral aggregate by weight of the total board composition, pressing and drying to produce an integrally formed multiply structural composition.

nited States Patent [191 Oshida et a1.

THERMAL AND ACOUSTICAL STRUCTURAL INSULATING COMPOSITION Inventors: OttoA. Oshida, Fountain Valley;

Michael Shawgo, Buena Park, both of Calif.

Assignee: Grefco, Inc., Philadelphia, Pa.

Filed: Mar. 9, 1972 Appl. No.: 233,285

Int. Cl. D2lf 11/00 Field of Search 162/129, 145, 123, 162/125, 181 R,181 C, 184, 300; 161/152, 158, 236, 237, 403

References Cited UNITED STATES PATENTS Dec. 18, 1973 3,373,074 3/1968DEustachio et a1. 161/236 1,921,369 8/1933 Massey 162/184 FOREIGNPATENTS OR APPLICATIONS 805,636 2/1969 Canada 161/152 PrimaryExarriiner-S. Leon Bashore Assistant Examiner-Peter ChinAttorney-Everett H. Murray, Jr. et a1.

[5 7 ABSTRACT A coated thermally expanded mineral aggregate thermal andacoustical insulating structural composition and a process for itsproduction is provided wherein a low consistency board furnishcontaining binder, defibrillated fibrous material and a relatively highpercentage of glass reinforcing fibers is deposited on the surface of apartially dewatered mat containing defibrillated fibrous material,binder and 50-85 percent thermally expanded mineral aggregate by weightof the total board composition, pressing and drying to produce anintegrally formed multiply structural composition.

14 Claims, No Drawings THERMAL AND ACOUSTIGAL STRUCTURAL INSULATINGCOMPOSITION The invention relates generally to thermal and acousticalinsulating compositions, especially those compositions useful asstructural insulation and acoustical tile.

lnsulating products have been known for many years, especially thoseincorporating various inert types of mineral aggregates, fibrousmaterials and assorted binders. An example of inert types of mineralaggregate includes exfoliated vermiculite and expanded perlite. Perliteis a form of glassy rock similar to obsidian, usually containing, 65 to75 percent silicon dioxide, to percent aluminum trioxide, and 2 to 5percent water. When perlite is heated to the softening point, it expandsto form a light, fluffy material similar to pumice. Vermiculite is amineral of the mica group; however, it is hydrated and has the propertyof expanding six to twenty times its volume when heated to about 2,000F.Basically, it is a hydrated m'agnesium-aluminum-iron silicate whichcontains small quantities of other minerals. Perlite is a generic termfor'the above noted glasses of the volcanic type, which upon beingheated to controlled temperatures expand to form lightweight particlespossessing good thermal and sound insulating qualities. Further, it hasbeen known that both the expanded perlite and the exfoliated or expandedvermiculite possess special qualities when used in conjunction withfibrous material and select binders for manufacturing lightweightinsulating boards of various types. Certain of these products have beenfound to be extremely useful as roofboard insulators as well asacoustical tiles and have included a large proportion of either thevermiculite or the perlite mineral aggregate, a relatively lowproportion of .fibrous material, i.e., an amount proportional to thestrength contributing properties of this ingredient, and sufficientbinder to hold the aggregate and the fibers firmly together in adimensionally stable structural board composition.

Such products have generally been formed using the wet process whichinvolves. preparation of a water slurry of the board ingredients,defibrillation of the fibrous material, uniform suspension of the solidsthroughout the slurry through agitation, de-watering the slurry bypassing it over, e.g.,"a drainage screen or the like to produce a feltedwetboard, lightcompression of the wet board to consolidate and impartuniform thickness thereto, followed by drying of the formed board. Theinstant invention modifies the above described process notably bypartially dewatering the felted board prior to application of a thincoating to the still-wet board after it has been consolidated somewhatto insure uniform thickness. Ultimately the board is de-watered, pressedto uniform thickness and dried as in the above process. The boardforming slurries containing the mineral aggregates'discussed above havevery favorable de-watering properties which render the slurriesadvantageously freefiltering in nature.

The end result is a multi-component insulating board containing amineral aggregate, fibers and a binder wherein an inter-entangled massof loose fibriliated fibers entrap and hold the particles of the mineralaggregate in a spaced relationship throughout the structural insulationboard.

Some of the recognized shortcomings of thermal and acoustical structuralinsulation board, especially of the perlite type insulation board, havebeen poor strength properties in the top surface of the board, easilyabradable top and bottom board surface and high absorption orpenetration of hot-mopped asphalt into the board, thereby requiringgreater amounts of asphalt for bonding. These shortcomings have at timeresulted in (inadequate) bond strength between the roofing membrane andthe top surface of the insulation board or between the bottom surface ofthe insulation board and the roof back.

These shortcomings have been alleviated somewhat through the developmentof an asphalt-clay coating for application to the top surface of theinsulation board resulting in minor improvement in board strengthproperties. However, recently a more economical two-ply roofing systemhas been introduced creating a new problem of roofing membrane splittingdue to thermal expansion and contraction resulting from large variationsin outside temperature. With some glass fiber boards these splits havebeen reported to occur at the abutted joints of the boards but theproblem has been mollified by taping the joints. Similar splits inroofing membranes have been reported in the Permalite-type boards butassume no distinct pattern with the splits causing the board itself tobreak thereby resulting in a fissure extending through the top surfaceof the board to the lower surface abutting the roof back. Thisunpredictable random splitting of the membrane has again been attributedto insufficient board strength properties, especially at the top surfaceof the Permalite-type thermal and acoustical insulation boards.

The two-ply roofing system is used frequently despite the above noteddeficiencies. The general purpose of this invention is to provide majorstrength improvements in the Perlite-type thermal and acousticalinsulation board which will overcome the above-noted deficiencies.Fundamentally, this is accomplished by applying a relatively thincoating of a defibrillated cellulosic fibrous material as a reinforcingfiber and a binder also containing other additives over the top surfaceof a mat deposited on a board forming machine which would alsocomprisebasically a defibrillated cellulosic fibrous material and abinder, whereby the coating is applied at'the wet endo'f the boardforming process and forms a coating or skin as an integral part of theboard, thereby eliminating a laminating process.

OBJECT OF THE INVENTION It is a primary object of the present inventionto improve uponthe prior art structural insulating compositions byproviding a composition which has all of their advantages, includinglight weight, ease of formation in the wet process i and additionallypossessing substantially improved insulating qualities as well assubstantially improved board strength, by applying a coating to at leastone major surface of the wet mat during the board forming process.

It is an additional object of this invention to provide a coating forsuch structural board, which coating contains mineral fibers, e.g.,glass, rock, slag and asbestos fibers thereby eliminating warping causedby excessive shrinkage during the drying process and materiallyincreasing the surface strength of the resultant insulation board.

It is the further object of this invention to provide a process forapplying a coating or skin to the surface of the wet mat board duringthe board-forming process,

which coating becomes an integral part of the board thereby eliminatinga laminating step.

lt is an additional object to provide a process for forming structuralinsulation boards which are coated as well as those which aremultiple-ply having dissimilar board compositions in different strata.

A further object of this invention is to provide a general purposeinsulating board having especially good heat and sound insulatingqualities, while combining optimally low weight per unit volume withadequately high flexural strength.

SUMMARY OF THE INVENTION A thermal and acoustical insulating compositionand a process for its production are provided wherein the compositioncomprises, inter alia, a mineral aggregate, a defibrillated organicfibrous material and a binder wherein the insulating composition is inthe form of structural insulating board and a coating containing mineralfibers is applied to at least one major surface of the structuralinsulating composition.

Additionally, a process for producing the coated thermal and acousticalinsulating structural material is provided which involves adequatelymixing a'thermally expandable mineral aggregate, a defibrillated organicfibrous material and a binder, depositing a sufficient amount of saidcomposition on a board forming machine to form a mat of desiredthickness and consistency, partially de-watering the mat, applying tothe still-wet surface of the mat a coating containing organic fibers anda binder followed by de-watering, pressing and drying the mat to producethe coated thermal and acoustical insulating structural material.

More specifically, the invention comprises a thermal and acousticalinsulating composition which is produced from a thermally expandablemineral aggregate such as perlite or exfoliated vermiculite, adefibrillated cellulosic fibrous material, such as cellulosic pulp, anda binder which is generally bituminous in nature, in a slurry which isdeposited on a board-forming machine in the wet state and partiallyde-watered. Subsequent to the partial de-watering, a coating is appliedto the stillwet deposited mass wherein the coating contains adefibrillated organic fibrous material such as pulp, a binder which isgenerally bituminous in nature, clay, starch, and glass fibers inaddition to other additives which may improve fire retardant propertiesof the resultant board. These additives may include among others, boricacid, borax, ammonium sulfate, and various phosphates which allcontribute generally to improve the fire retardance. The limitation tobe considered with particular regard to fire retardant promoters is theadverse effect that these water soluble additives-have on the waterabsorption property of the resultant board. The coating is of a lowconsistency, that is, a low solids coating possessing a high percentageof glass fibers for reinforcement and ultimately provides an insulationmaterial with a tough coating on its surface which imparts greatlyimproved strength properties to the board. Not only have the specificingredients of our insulating composition been selected and combinedwith care, so too have the proportions of ingredients been chosen togive optimum results.

Our invention also comprises use of the following ranges (Table l) ofproportions by total weight of final dry insulating composition and bytotal weight of final dry coating composition used thereon:

TABLE 1 Percent Percent of Board of Ingredients Ingredients Substrate inCoating Thermally expandable 50-85 NONE mineral aggregate IDefibrillated organic l0-30 40-80 fibrous material Bituminous Binderl-l2 5-20 Clay 0.l8 2.0-15 Starch none l.0- l 0 Glass fibers none 0.|-|0

Various other additives may be included in the abovenoted composition toimprove qualities commensurate with the qualities and the degree towhich they are improved.

Some additives may improve particular aspects such heat by convectionand conduction. It also contributes to the compressive and tensilestrength of the board as well as to its indentation resistance.

The expanded mineral aggregate used in conjunction with this inventionshould be in particle form having an apparent bulk density of about 2through 8 pounds per cubic foot, although departures from these rangesmay be made in appropriate circumstances. Mesh sizes of the expandedmineral aggregate should range from about 20 to about 200 mesh foroptimum performance, however, other sizes may also be utilized as well.

The fibers used herein are usually obtained from wood; however,cellulosic fibers are used depending upon the supply. For example, cornstalks, sugar cane, wastepaper fibers repulped broke or the like may beutilized. in addition, non-cellulosic fibers my be utilized eitherexclusively or in combination with cellulosic fibers. For purposes ofsimplicity the description will be confined to cellulosic fibers and itwill be understood that other fibers may be used while remaining withinthe scope of this invention.

Fibrous substances used within the purview of the instant invention areall used in their defibrillated or individualized state. They includevarious organic fibers such as newprint pulp, bagasse and others. Ofcourse these fibers are not limited to organic or cellulosic fibers.Other fibrous material may be used dispersed in the slurry which are notorganic, such as asbestos, rock, slag and glass fibers. They too mayimprove strength characteristics of the board in addition to fireretardancy characteristics. The fibrous material is dispersed in theboard-making slurry such that the individual fibers are separated fromone another, thus assuring their presence in the final board compositionand coating as a mass of inter-entangled fibers'which surround theaggregate particles as well as the other components of the board slurry.Long or short fibers may be used equally-well or a mixture of fibers ofdifferent lengths may be employed successfully. However, for optimumresults the fibers in the board should be from 1 to 5 millimeters longand 5 to 30 microns in diameter, while those fibers utilized in thecoating should be from 3 to 30 millimeters long and from 5 to '30microns in diameter.

Various examples of materials which can be utilized principally asbinders, however which may contribute other favorable characteristics tothe substrate composition useful in practicing the instant inventionused either alone or in combination, are clays such as kaolin or chinaclay, ball clay, fire clay, stoneware clay, bentonite, fullers earth,activated clays, dusting clays,

bleaching clays, calcined clays, colloidal clays, enamel clays andfiller clays; starch may be used and various bituminous additives suchas asphalt may be added either as a solid or in the form of an emulsion.Other materials having similar properties in accomplishing similareffects may be utilized in the practice of the instant invention.Particularly advantageous in the practice of this invention is asphaltas the binder, along with bentonite clay and starch.

The amount of binder used in the insulation board is indicated as atfrom 1 to 12 percent and in the coating from 5 to percent which are dryweights of the final composition. Bentonite clay is, of course,incombustible and its use enhances the fire resistance of the board. Italso functions as a water repellant inasmuch as it swells in thepresence of water and thereby tends to fill surrounding board void, sothat further take-up of water by the board becomes more difficult. Ifstarch is employed as a binder it is possible to use minimum quantitiesof fibrous material to thereby lighten the board and improve its fireresistance. Asphalt is inexpensive, easy to use and functionssufficiently well as a binding material, in addition to its addedquality of improving water repellancy of the final insulating board. Itis certainly within the perview of this inventionto use variouscombinations of these materials to give an advantageously improvedproduct. An example of this is the combination of bentonite clay andstarch which improves the fire resistance of the board while assuringhigh binding strength. Similarly, the use of bentonite clay inconjunction with asphalt improves the fire resistance and moistureresistance of the board.

The primary advantage of the,.instant invention is the notable strengthimprovements in the thermal and acoustical insulating composition boarddiscussed above, which strength increase is obtained by applying a thincoating of a fibrous furnish, i.e. coating, to the surface of the wetmat laid down from the slurry on the board forming machine during theboard forming process and prior to the de-watering, pressing and dryingoperations. The process, as noted above, involves adequately mixing thethermally expanded mineral aggregate, a defibrillated, preferablycellulosic fibrous material, a binder and clay in an aqueous slurry;depositing a sufficient amount of said composition on a board formingmachine to form a mat of the desired thickness and consistency,partially de-watering said mat, and applying to the still-wet surface ofthe mat a coating comprising basically, pulped newsprint and asphaltemulsion with additives of glass fibers, starch, clay etc.

The wet mat is then passed under a head box which lays the fibrouscoating of the present invention onto the wet surface of the mat. Thecoating may be rollercoated, or it may be applied through a plurality ofsprays fed from a pressurized supply source or it may be applied in abrushing operation. The mat had sufficient body after partial dewateringto receive the coating without marring its surface or displacing thefibers. When a roller coater is used, a source supply continuously feedsthe coating to the coating machine to insure application of a properthickness of coating to the board substrate. The wet board is thenfurther dewatered, pressed and dried to form the structural insulationboard. Several embodiments of the invention have been described in somedetail below in order to enable those skilled in the field to apprehendfully the principles and to produce such units using only the ordinaryskills of their specialty. No inference, however, should be drawn fromthe detailed character of the description that the invention is limitedin its employment to any such details of composition or procedure. Onthe contrary, a wide variety of embodiments is possible, as will readilyoccur to those skilled in this field and the intention is to cover allalternatives, substitutions and equivalents only within the spirit andscope of the invention as expressed in the appended claims. Theinvention is further illustrated by the following examples in which allparts and percentages are by weight unless otherwise indicated. Thesenon-limiting examples are illustrative of certain embodiments designedto teach those skilled in the art how to practice the invention and torepresent the best mode contemplated for carrying out the invention.

EXAMPLE I The following example illustrates the preparation of thecoated thermal and acoustical insulating structural compositiondiscussed in the foregoing.

Pulped newsprint in such a proportion as to constitute 22 1% percent byweight of the final dry board is added to water to make a diluted paperpulp slurry. An appropriate amount of binder, in this instance 5 percentby weight of an asphalt binder, is added to the aqueous pulp slurry.Twenty percent of the pulped newsprint-asphalt requirement is thenremoved for subsequent use as the coating for the board being prepared.Glass fibers are then added to the coating composition in a sufficientamount to constitute 2.5 percent of the coating composition in the finalproduct. The fibers ranged in length from 3 to 30mm and in diameterfrom'S microns to 30 microns. The thermally expanded mineral aggregate,viz. perlite, is added in the amount to constitute percent of the finaldry weight of the board to the remaining pulped newsprint-asphaltcomposition. The pulped newsprint-asphalt-perlite is then mixed inaccordance with standard procedure for the preparation of insulationboard. The composition, that is, the board furnish, is then placed onthe board former and de-watered only sufficiently to remove the surfaceglaze. This fixes the wet mat in place and minimizes any erosion of themat during the placing of the coating furnish or composition on itssurface. The coating, including the glass fibers, is then applied to thewet mat substrate by flowcoating although any other suitable means isacceptable, the formed mat with the surface coating is then furtherde-watered under vacuum followed by pressing to a thickness of one inchand drying overnight at a temperature of 230F- The resulting board inthis example and the remaining examples was approximately one inchthick, with a density of from about 8'to about 10 poundsper cubic footand a wet board solids level of 20 to 25 percent.

EXAMPLE 2 In this example, substantially the same procedure was followedas that utilized in Example 1. The percentage of the components and theappropriate data obtained as a result of tests is indicated in Table 11.

TABLE II A B Board Formula Coating Formula Pcrlitc 70 Pulpcd Newsprint61.0 Newsprint (pulped) 22.5 Asphalt 13.5 Asphalt 5.0 Clay (Bcntonitc)7.0 Clay (Bentonitc) 2.5 Starch 5.3 Glass Fibers 2.6 Boric Acid 5.3Borax 5.3

Additives of clay and starch used in the coating of the insulation boardexhibit significant improvements in the strength both to the top surfaceand the bottom surface of the board indicating adequate migration of thestarch through the board. The addition of the glass fibers to thecoating also prevents or significantly retards the tendency of theboards to warp during the drying process as a result of excessiveshrinkage in the board coating. The glass fibers not only reduced oreliminated the problems of warping, but also imparted additionalstrength to the coated surface board. To improve the fire resistantproperties of the coated board due to the high percentage of organicmaterials in the board, additives such as boric acid, borax, ammoniumsulfate and various phosphates may be included. The most favorableresults, as indicated herein, are generally obtained with the combinedmixture of boric acid and borax. Usage of fire retardant materials toeffect better fire resistant properties is limited by the adverse effectof these water soluble additives on the water absorption properties ofthe board.

The modulus of rupture (MOR) for coated boards having a density of tenpounds per cubic foot, when broken in tension on the top surface,exhibited an average strength increase of 125 percent (83-188 pounds persquare inch). For bottom surface breaks, the strength increases were notas great but were still quite significant averaging some 55 percent(that is, 85-131 pounds per square inch). Strength increases for coatedboards at an 8 pound density range averages 134 percent (61-143 poundsper square inch) and 46 percent (61-89 pounds per square inch) for thetop and bottom surface breaks respectively. Tests for internal bondstrength also exhibited strength improvements of some 12 percent(10.1-13.1 pounds per square inch) and 17 percent (11.2-13.1 pounds persquare inch) for the coated over the uncoated laboratory boards atdensities of 8-10 pounds per cubic foot, respectively.

The test methods used were as follows: the modulus of rupture is asoutlined in ASTM-C-203, except that 2 inch X 6 inch specimens weretested on a 4 inch span instead of 3 inch X 12 inch specimens on a 10inch span; internal bond (tensile strength perpendicular to boardsurface) is as described in ASTM-C-209, except that 2 inch X 2 inchspecimens were used instead of 12 inch X 1 2 inch; inclined panelfiametest used is that outlined in ASTM-C-209, except for 6 inch X 6inch sasq ssa r sed s ad. 2 2 E inc Any of the various available boardforming machines may be employed for forming boards described herein ona commercial sacle, including the Fourdrinier machine, rotary vacuumfilters or cylinder-type board machines, all of which operatecontinuously, and suction mold-type equipment.

The principles, preferred embodiments, and modes of operation of thepresent invention have been described in the foregoing specification.The invention which is intended to be protected herein, however, is notto be construed as limited to the particular forms disclosed, sincethese are to be regarded as illustrative rather than restrictive.Variations and changes may be made by those skilled in the art withoutdeparting from the spirit or scope of the present invention.

What is claimed is:

1. A thermal and acoustical insulating composition comprising athermally expanded mineral aggregate, a defibrillated fibrous material,and a binder wherein said insulating composition is in the form of astructural insulating board and wherein a coating containing glassfibers, a binder, and defibrillated fibrous materials, is applied to atleast one major surface of such structural insulating board.

2. The thermal and acoustical insulating composition of Claim 1comprising a thermally expanded mineral aggregate, a defibrillatedcellulosic fibrous material and a binder and wherein said coatingcomprises a defibrillated organic fibrous material, clay, a binder andglass fibers.

3. The thermal and acoustical insulating composition of Claim 2 whereinsaid binder is bituminous.

4. The thermal and acoustical insulating composition of Claim 2 whereinsaid defibrillated organic fibrous material is cellulosic.

5. A thermal and acoustical insulating composition comprising from about50 to about 85 percent thermally expanded mineral aggregate, from about10 to about 30 percent defibrillated cellulosic fibrous material, fromabout 1 to about 12 percent bituminous binder, wherein said compositionis in the form of a structural insulating board having a coating thereoncomprising from about 40 to about percent defibrillated cellulosicfibrous material, from about 5 to about 20 percent bituminous binder,from about 2 to about 15 percent clay and from about 1 to about 8percent glass fibers.

6. A composition of claim 6 wherein the defibrillated cellulosic fibrousmaterial is selected from the group consisting of pulped newsprint,pulp, kraft paper pulp, and bagasse, the bituminous binder is asphalt,the clay is selected from the group consisting of kaolin or china clay,ball clay, fire clay, stoneware clay, bentonite, fullers earth,activated clays, dusting clays, bleaching clays, calcined clays,colloidal clays, enamel clays and fuller clays, and the glass fibers areless than 1.5 inches long having a diameter not in excess of 50 microns.

7. A composition of claim 6 wherein the defibrillated cellulosic fibrousmaterial is pulped newsprint, and the clay is bentonite.

8. A coated thermal and acoustical insulating board comprising a mineralaggregate selected from the group consisting of thermally expandedaluminosilicate rocks including perlite, and exfoliated vermiculite; aclay selected from the group consisting of kaolin, ball clay, fire clay,bentonite, activated clays, calcined clays, and fuller clays; and pulpednewsprint wherein said insulating board has applied to at least onemajor surface thereof a coating comprising pulped newsprint, abituminous binder, clay, starch and glass fibers.

9. A coated perlite or exfoliated vermiculite thermal and acousticalinsulating board comprising, on a dry basis, from about to 30 percentpulped newsprint, from about 01. to about 8 percent bentonite clay, fromabout 1.0 to about 12 percent asphalt, and from about 50 to about 85percent of a material selected from the group consisting of exfoliatedvermiculite and perlite, wherein the structural insulating board hasapplied to one major surface thereof a coating comprising from about 40to about 80 percent pulped newsprint, from about 5 to about 20 percentasphalt, from about 2 to about percent bentonite, from about 1 to about15 percent starch, from about 1 to about 8 percent glass fibers, fromabout 1 to about 8 percent boric acid, and from about 1 to about 10percent borax,

10. A coated perlite thermal and acoustical insulating board, comprisingon a dry basis, 70 percent thermally expanded perlite, 22 percent pulpednewsprint, 5 percent asphalt, and 3 percent Wyoming bentonite claywherein said substrate has applied to at least one major surface thereofa coating comprising 62 percent pulped newsprint, l4 percent asphalt, 6percent Wyoming bentonite, 5 percent starch, 3 percent glass fibers, 4percent boric acid, and 6 percent borax.

111. A process for producing coated thermal and acoustical structuralmaterial comprising:

a. mixing a thermal expanding aggregate, defibrillated cellulosicfibrous material, a binder and clay;

b. Depositing a sufficient amount of said composition on a board-formingmachine to form a mat of desired thickness and consistency;

c. Partially dewatering said mat in amounts sufficient to remove thewater glaze therefrom;

d. Applying to the still wet surface of the deposited mass a coatingcomprising glass fibers, defibrillated cellulosic fibers, clay, andbinder; and then e. Dewatering, pressing and drying said mass.

12. The process of claim I] wherein the defibrillated cellulosic fibrousmaterial is selected from the group consisting of pulped newsprint,pulp, kraft paper pulp, and bagasse; the thermally expandablealumino-silicate rocks including perlite and vermiculite, the bituminousbinder is asphalt; the clay is selected from the group consisting ofkaolin or china clay, ball clay, fire clay, bentonite, fullers earth,activated clays, dusting clay, calcined clays, colloidal clays, andfiller clays, and the glass fibers are less than 1 /2 inches long havinga diameter not in excess of 30 microns.

13. The process of Claim 11 wherein the thermal acoustical insulatingcomposition comprises from about 50 to about 85 percent thermallyexpanded mineral aggregate, from about 10 to about 30 percentdefibrillated cellulosic fibrous material, from about 1 to about 12percent bituminous binder, wherein said composition is in the form of astructural insulating board having a coating applied to at least onemajor surface thereof which comprises from about 40 to about percentdefibrillated cellulosic fibrous material, from about 5 to about 20percent bituminous binder, from about 2 to about 15 percent clay andfrom about I to about 8 percent glass fibers.

14. The process of claim 11 wherein the thermal acoustical insulatingcomposition comprises, on a dry basis, from about 50 to about percentthermally expanded perlite, from about 10 to about 30 percent pulpednewsprint, from about 1 to about 12 percent asphalt, from about 0.1 toabout 8 percent bentonite clay, and wherein the coating applied to themajor surface thereof comprises from about 40 to about 80 percent pulpednewsprint, from about 5 to about 20 percent asphalt, from about 2 toabout 15 percent bentonite, from about 1 to about l0 percent starch,from about 1 to about 8 percent glass fibers, from about 1 to about 8percent boric acid and from about 1 to about 10 percent borax.

Notice of Adverse Decision in Interference In Interference No. 99,545involving Patent No. 3,7 7 9,860, O. A. Oshida and M. Shawgo, THERMALAND ACOUSTICAL STRUCTURAL INSULAT- ING COMPOSITION, final judgmentadverse to the patentees Was rendered. July 17,1978,as to claims 1, 2, kand 11.

[Ofitcial Gazette October 17, 1.978.]

2. The thermal and acoustical insulating composition of Claim 1comprising a thermally expanded mineral aggregate, a defibrillatedcellulosic fibrous material and a binder and wherein said coatingcomprises a defibrillated organic fibrous material, clay, a binder andglass fibers.
 3. The thermal and acoustical insulating composition ofClaim 2 wherein said binder is bituminous.
 4. The thermal and acousticalinsulating composition of Claim 2 whereiN said defibrillated organicfibrous material is cellulosic.
 5. A thermal and acoustical insulatingcomposition comprising from about 50 to about 85 percent thermallyexpanded mineral aggregate, from about 10 to about 30 percentdefibrillated cellulosic fibrous material, from about 1 to about 12percent bituminous binder, wherein said composition is in the form of astructural insulating board having a coating thereon comprising fromabout 40 to about 80 percent defibrillated cellulosic fibrous material,from about 5 to about 20 percent bituminous binder, from about 2 toabout 15 percent clay and from about 1 to about 8 percent glass fibers.6. A composition of claim 6 wherein the defibrillated cellulosic fibrousmaterial is selected from the group consisting of pulped newsprint,pulp, kraft paper pulp, and bagasse, the bituminous binder is asphalt,the clay is selected from the group consisting of kaolin or china clay,ball clay, fire clay, stoneware clay, bentonite, fuller''s earth,activated clays, dusting clays, bleaching clays, calcined clays,colloidal clays, enamel clays and fuller clays, and the glass fibers areless than 1.5 inches long having a diameter not in excess of 50 microns.7. A composition of claim 6 wherein the defibrillated cellulosic fibrousmaterial is pulped newsprint, and the clay is bentonite.
 8. A coatedthermal and acoustical insulating board comprising a mineral aggregateselected from the group consisting of thermally expandedalumino-silicate rocks including perlite, and exfoliated vermiculite; aclay selected from the group consisting of kaolin, ball clay, fire clay,bentonite, activated clays, calcined clays, and fuller clays; and pulpednewsprint wherein said insulating board has applied to at least onemajor surface thereof a coating comprising pulped newsprint, abituminous binder, clay, starch and glass fibers.
 9. A coated perlite orexfoliated vermiculite thermal and acoustical insulating boardcomprising, on a dry basis, from about 10 to 30 percent pulpednewsprint, from about
 01. to about 8 percent bentonite clay, from about1.0 to about 12 percent asphalt, and from about 50 to about 85 percentof a material selected from the group consisting of exfoliatedvermiculite and perlite, wherein the structural insulating board hasapplied to one major surface thereof a coating comprising from about 40to about 80 percent pulped newsprint, from about 5 to about 20 percentasphalt, from about 2 to about 15 percent bentonite, from about 1 toabout 15 percent starch, from about 1 to about 8 percent glass fibers,from about 1 to about 8 percent boric acid, and from about 1 to about 10percent borax.
 10. A coated perlite thermal and acoustical insulatingboard, comprising on a dry basis, 70 percent thermally expanded perlite,22 percent pulped newsprint, 5 percent asphalt, and 3 percent Wyomingbentonite clay wherein said substrate has applied to at least one majorsurface thereof a coating comprising 62 percent pulped newsprint, 14percent asphalt, 6 percent Wyoming bentonite, 5 percent starch, 3percent glass fibers, 4 percent boric acid, and 6 percent borax.
 11. Aprocess for producing coated thermal and acoustical structural materialcomprising: a. mixing a thermal expanding aggregate, defibrillatedcellulosic fibrous material, a binder and clay; b. Depositing asufficient amount of said composition on a board-forming machine to forma mat of desired thickness and consistency; c. Partially dewatering saidmat in amounts sufficient to remove the water glaze therefrom; d.Applying to the still wet surface of the deposited mass a coatingcomprising glass fibers, defibrillated cellulosic fibers, clay, andbinder; anD then e. Dewatering, pressing and drying said mass.
 12. Theprocess of claim 11 wherein the defibrillated cellulosic fibrousmaterial is selected from the group consisting of pulped newsprint,pulp, kraft paper pulp, and bagasse; the thermally expandablealumino-silicate rocks including perlite and vermiculite, the bituminousbinder is asphalt; the clay is selected from the group consisting ofkaolin or china clay, ball clay, fire clay, bentonite, fuller''s earth,activated clays, dusting clay, calcined clays, colloidal clays, andfiller clays, and the glass fibers are less than 1 1/2 inches longhaving a diameter not in excess of 30 microns.
 13. The process of Claim11 wherein the thermal acoustical insulating composition comprises fromabout 50 to about 85 percent thermally expanded mineral aggregate, fromabout 10 to about 30 percent defibrillated cellulosic fibrous material,from about 1 to about 12 percent bituminous binder, wherein saidcomposition is in the form of a structural insulating board having acoating applied to at least one major surface thereof which comprisesfrom about 40 to about 80 percent defibrillated cellulosic fibrousmaterial, from about 5 to about 20 percent bituminous binder, from about2 to about 15 percent clay and from about 1 to about 8 percent glassfibers.
 14. The process of claim 11 wherein the thermal acousticalinsulating composition comprises, on a dry basis, from about 50 to about85 percent thermally expanded perlite, from about 10 to about 30 percentpulped newsprint, from about 1 to about 12 percent asphalt, from about0.1 to about 8 percent bentonite clay, and wherein the coating appliedto the major surface thereof comprises from about 40 to about 80 percentpulped newsprint, from about 5 to about 20 percent asphalt, from about 2to about 15 percent bentonite, from about 1 to about 10 percent starch,from about 1 to about 8 percent glass fibers, from about 1 to about 8percent boric acid and from about 1 to about 10 percent borax.